Connection system for joining rectangular wall frames

ABSTRACT

A connection system for joining rectangular wall frames fabricated from pairs of rectangular cross section tubular side frame members and rectangular cross section tubular top and bottom frame members utilizes identical connectors, such as a single size machine screw and identical threaded inserts to provide upper and lower interconnections. Three different interconnections can be made using the single size machine screw and insert, the latter inserted into the open upper ends of the rectangular cross section tubular side frame members. Frame closure panels can be attached in a simple and secure manner.

BACKGROUND

Many types of modular enclosures for commercial and industrial useutilize modular rectangular frames of varying sizes to provide supportfor wall panels, shelving, work surfaces and the like. The modularframes may be interconnected to provide extended length walls,countertops or shelves. These variations may require special connectionsalong the length of an extended wall or at right angle corners. All ofthese variations in the modular construction often require specialfasteners of varying sizes and types resulting in complex and difficultto assemble modules.

SUMMARY

In accordance with the disclosure herein, a connection system forjoining rectangular wall frames that are fabricated from pairs ofrectangular cross section tubular side frame members and tubular top andbottom frame members utilizes identical connectors that comprise asingle size machine screw and identical inserts with coaxial threadedbores on opposite ends. The main interconnections utilize only abuttingside frame members, the connecting cross frame members being of aslightly smaller cross section. The results are simple interconnectionsthat provide significant savings in assembly time and cost. Therectangular wall frames carry easily assembled wall panels that are slidvertically into place between the vertical side frame members of a wallframe. The tubular top and bottom frame members are welded to thevertical side frame members and, for larger wall frames, an intermediatehorizontal frame member may be utilized.

The wall frames may be closed on either or both of their inner and outerfaces with closure panels that are easily inserted through a verticalslot between the side frame members and the top and bottom framemembers.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1-3 are top plan views of each of the three side frameinterconnections used for joining the rectangular wall frames.

FIG. 4 is a perspective view of a subassembly of wall frames using theFIG. 1 interconnection.

FIG. 5 is an enlarged detail of the connection shown in FIG. 4.

FIG. 6 is a perspective view of another wall frame subassembly utilizingthe interconnection of FIG. 2.

FIG. 7 is an enlarged detail of the connection shown in FIG. 6.

FIG. 8 is a perspective view of a wall frame subassembly using theinterconnection of FIG. 3.

FIG. 9 is an enlarged detail of the connection shown in FIG. 8.

FIG. 10 is an enlarged top plan view similar to FIG. 1 showing theconstruction and attachment of closure panels to the rectangular frame.

FIG. 11 is another perspective view of the side frame assembly 31 ofFIG. 8 rotated 90°.

FIG. 12 is a perspective view similar to FIG. 11 showing the positioningof frame closure panels.

FIG. 13 is a side elevation view of the arrangement shown in FIG. 12.

DETAILED DESCRIPTION OF THE SEVERAL EMBODIMENTS

FIGS. 1, 4 and 5 show a first and most basic side frame interconnection10 in accordance with this disclosure. In this embodiment, a longer wallframe 11 is attached perpendicularly to a narrower wall frame 12 usingthe first side frame interconnection 10. Each of the wall frames 11 and12 includes a pair of rectangular cross section tubular side framemembers 13 to which are welded a horizontal tubular top frame member 14and a tubular bottom frame member 15. The longer wall frame 11 mayinclude an intermediate cross frame member 16 for additional strengthand rigidity. Apart from variations in length, the side frame members 13are essentially the same, and the top, bottom and intermediate crossframe members are also substantially the same. In one embodiment, theside frame members 13 have 1 inch×2 inches cross sections. The tubulartop, bottom and intermediate frame members 14-16 have nominal crosssections of 1 inch×1½ inches.

Identical first side frame interconnections 10 are used to connect thewall frames 11 and 12 at their top and bottom ends. The side framemembers 13 are connected with the narrow face 17 of one side framemember in abutting contact with the wide face 18 of the other side framemember 13. A threaded insert 20 has coaxial threaded bores 21 onopposite ends and has a generally rectangular body adapted to fitsnuggly in the rectangular open end 22 of the side frame member 13. Boththe threaded bores 21 in the insert 20 may be tapped; however, it ispreferable to make the insert of plastic material and press a nut 23into counterbores on opposite ends of the insert. The insert body isprovided with a series of parallel thin flexible flaps 24 which deflectupon insertion of the insert and hold the insert tightly in place. Aflat top 25 on the insert provides a suitable closure.

With the insert in place, a machine screw 26 is inserted throughsuitable holes 27 in the wide faces 18 in one side frame member 13 andan aligned hole 28 in the narrow face 17 of the abutting side framemember 13. The machine screw 26 is suitably tightened and the provisionof an identical connection at the bottom ends of the side frame members13 provide a rigid and secure connection. Referring briefly to FIG. 7,the holes 27 in the wide face 18 of the side frame member can beelongated, as shown, for adjustment purposes.

Although the arrangement of the various side frame members 13, inserts20, and machine screws 26 vary in positioning from one interconnectionto the others, the inserts 20 are all identical and the machine screws26 are also all identical.

FIGS. 2, 6 and 7 show a second side frame interconnection 30 that is anextension of the interconnection 10 of the previously describedembodiment. The second side frame interconnection 30 utilizes anadditional longer wall frame 11 and the two longer wall frames areseparated by and attached to a side frame member 13 of a narrower wallframe 12. The second side frame interconnection 30 of this embodiment,in addition to the longer wall frame 11, requires only an additionalpair of identical machine screws 26 for the upper and lower connections.The same insert 20 is used in this embodiment with the machine screw 26extending through the elongated holes 27 in the wide face 18 of the sideframe member 13 of the newly added wall frame 11. In other words,beginning with the first side frame interconnection 10, the conversionof that interconnection to the second side frame interconnection 30requires only the addition of an upper and a lower machine screw 26.

In FIGS. 3, 8 and 9, there is shown a third side frame interconnection31 that, again, utilizes components that are identical to those used inthe interconnections 10 and/or 30 described above. In this embodiment,two shorter wall frames 32 are connected to one leg of a double panelwall frame 33. In addition, wide faces 18 of the side frame members forthe shorter wall frames 32 are positioned in abutting contact. A pair ofinserts 20 are inserted into the open ends 22 of the abutting wide faces18 and a pair of machine screws 26 extends through the wide faces of theside frame member 13 of the double panel wall frame 33 and into thethreaded bores 21 of the pair of inserts 20. An identical pair ofmachine screws 26 cooperate with an insert pair 20 at the bottom of theinterconnection in the same manner.

The tubular bottom frame members 14 of the wall frames 11, 12, 32 and 33of each of the three interconnection embodiments may include verticallyadjustable leveling pads 34 that are threaded into suitable brackets 35attached to the undersides of the bottom frame members 15. Also, inorder to accommodate the support and connection to top surfaces, such ascountertops (not shown), the tubular top frame members 14 of certain ofthe frames 11, 12, 32 and 33 may be provided with riser brackets 36 toprovide additional support for a top panel to provide a top cap closeout and upper surface that is flush with the flat tops 25 of thethreaded inserts 20.

Referring to FIG. 10, there is shown a modified version of FIG. 1 inwhich the longer wall frame 11 is provided with a pair of frame closurepanels 37. Although two panels are used in this embodiment, only one isnecessary to provide a desired closure. Otherwise, the panels aremounted to the frame in an identical manner.

The frame closure panels 37 extend between the wide faces 18 of the sideframe members 13 and are held in position against side faces 38 of thetubular top frame member 14 and tubular bottom frame member 15. Toprovide a guide and securement for the closure panels 37, a pair ofvertical angle members 40 are attached to the wide faces 18 of opposedside frame members 13 and extend vertically between the top and bottomframe members 14 and 15. The free unattached leg 41 of the angle membersprovide tongues 42 that are spaced laterally from the frame member sidefaces 38 to define a slot 43 into which a frame closure panel 37 isinserted vertically to provide the closure. The other leg 44 of theangle member may be attached to the face of the side frame member 13with any suitable fasteners. To support the closure panel, a bottom stop45 extends horizontally from the wide faces 18 of side frame members 13at the bottom of the slot 43.

FIG. 11 is similar to FIG. 8 and shows a perspective view of a frameassembly using the side frame interconnection 31 of FIGS. 3, 8 and 9.However, the side frame assembly 31 of FIG. 11 also includes thevertical angle members 40 that are attached to the wide faces 18 of theside frame members 13 in a manner similar to that shown in FIG. 10. Thefree legs 41 of the angle members 40 define vertical slots 43 into whichclosure panels 37 are inserted as shown in FIGS. 12 and 13. The otherlegs 44 of the angle members 40 are attached to the wide faces 18 of theside frame members 13 between which the closure panels 37 extend.

As is best seen in FIGS. 12 and 13, each of the closure panels 37 has aback side supported against the frame members 13, 14 and 15 (as well asintermediate cross frame members 16, if used). The front face of theclosure panels are, as discussed above, supported in the slots 43 andagainst the free legs 41 of the angle members 40. A bottom stop 45 ineach frame panel provides a stop and support for the closure panels 37.

While the invention has been described with reference to a preferredembodiment, those skilled in the art will appreciate that certainsubstitutions, alterations and omissions may be made without departingfrom the spirit thereof. Accordingly, the foregoing description is meantto be exemplary only and should not be deemed limitative on the scope ofthe invention set forth with the following claims.

1. A connection system for joining rectangular wall frames fabricatedfrom pairs of rectangular cross section tubular side frame members andtubular top and bottom frame members, the system comprising: at leasttwo side frame members from two frames positioned with a narrow face ofone side frame member in abutting contact with a wide face of the otherside frame member; a side frame interconnection comprising an insertcaptured in the open end of said one side frame member, the inserthaving coaxial threaded bores on opposite ends, one of said boresadapted to receive a machine screw extending through both wide faces ofthe other side frame member, the narrow face of said one side framemember, and into the threaded bore at one end of the insert.
 2. Theinvention as set forth in claim 1, including a third frame positionedwith a wide face of a third side frame member in abutting contact withthe narrow face of said one side frame member; a third side frameinterconnection comprising a second machine screw extending through bothwide faces of said third side frame member, through the abutting narrowface of said one side frame member, and into the threaded bore at theother end of the insert.
 3. The invention as set forth in claim 1,including a third frame positioned with a wide face of the third sideframe member in abutting contact with the wide face of said other sideframe member; a third side frame interconnection comprising a secondinsert captured in the open end of said third side frame member, thesecond insert being identical to said first named insert; a secondmachine screw identical to said first named machine screw, extendingparallel thereto and through both wide faces of the other side framemember, through the narrow face of said third side frame member, andinto the threaded bore at one end of said second insert.
 4. A connectionsystem for joining rectangular wall frames fabricated from pairs ofrectangular cross section tubular side frame members and tubular top andbottom frame members, the system comprising: three side frame membersfrom three frames joined with two of said side frame members positionedwith their wider faces parallel to one another and interconnected by oneside frame member; the interconnection comprising an insert captured inthe open ends of said two side frame members or said one side framemember, the insert having coaxial threaded bores on opposite endsadapted to receive pairs of identical machine screws; the screwsextending through said one side frame member and into the threaded boresof inserts in the ends of said two side frame members or through saidtwo side frame members and into the threaded bores of the insert in theend of said one side frame member.
 5. The invention as set forth inclaim 4, wherein said two side frame members are positioned inface-to-face contact with their narrow faces lying coplanar, and thewide face of said one side frame member in overlying contact with saidnarrow faces.
 6. The invention as set forth in claim 4, wherein said twoside frame members are separated by said one side frame member with theopposed wide faces of said two side frame members in contact with theopposite narrow faces of said one side frame member capturedtherebetween.
 7. The invention as set forth in claim 4, wherein theframes are fabricated with weldments.
 8. The invention as set forth inclaim 4, wherein the wide faces of the side frame members are wider thanthe wide faces of the top and bottom frame members.
 9. The connectionsystem as set forth in claim 1, including a rectangular frame closurepanel placed to extend between the wide faces of opposed side framemembers of one frame and with a panel back face in contact with andextending between the side faces of the top and bottom frame members.10. The connector system as set forth in claim 9, including a pair ofnarrow tongues attached to the wide faces of the opposed side framemembers and extending between the top and bottom frame members, thetongues defining with the side frame members a slot of receipt of theclosure panel.
 11. The connection system as set forth in claim 10,wherein the tongues comprise the freely extending legs of angle membersthe other legs of which are attached to the wide faces of the opposedside frame members.
 12. The connection system as set forth in claim 11,wherein the frame closure panel is mounted in contact with the outerside faces of the top and bottom frame members.
 13. The connectionsystem as set forth in claim 12, comprising a second frame closure panelmounted in contact with the inner side faces of the top and bottom framemembers.
 14. The connection system as set forth in claim 12, including abottom stop supporting the lower edge of the closure panel at the lowerend of the slot.